Producing composite mouldings using pre-preg laminating techniques

This standard identifies the competences you need to produce composite mouldings (such as moulds, components, splashes, jigs) using pre-preg laminating techniques, in accordance with approved procedures. You will be required to follow the appropriate instructions, drawings, specifications and documentation to produce the various mouldings, using the correct pre-preg laminating production techniques.

You will produce a range of composite mouldings, incorporating a variety of features and using a range of techniques and processes. Mouldings produced will include laminates and sandwich structures, using a range of resin, fibre and core materials.

Your responsibilities will require you to comply with organisational policy and procedures for the pre-preg laminating activities undertaken, and to report any problems with the production activities, equipment or materials that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to applying pre-preg laminating techniques and procedures. You will have an understanding of the pre-preg laminating production techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, recognising faults, and ensuring the work output is to the required specification.

You will understand the safety precautions required when carrying out the pre-preg laminating activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct component drawing or any other related specifications for the component to be produced
3. determine what has to be done and how this will be achieved
4. obtain and prepare the appropriate tools, equipment and materials
5. carry out the moulding activities using the correct methods and techniques
6. produce mouldings to the required specification
7. complete relevant production documentation
8. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. health and safety precautions to be taken, and procedures used in the specific work area, when working with composite materials, consumables, tools and equipment
2. the hazards associated with working with composite materials, consumables, tools and equipment, and how to minimise these and reduce any risks in the work area
3. protective equipment (PPE) that is needed for personal protection and, where required, the protection of others
4. the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
5. the specific environmental conditions the must be observed when producing composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment)
6. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
7. how to interpret drawings/lay up manuals, systems of measurement, workpiece reference/datum points and system of tolerancing
8. quality procedures used in the workplace to ensure production control (such as in relation to currency, issue, meeting specification)
9. conventions and terminology used for pre-preg laminating techniques (such as material orientation, material identification, material templates, ply lay-up, pressure plates, vacuum bagging, cure cycles, exotherm)
10. the function resins, reinforcement, catalysts, accelerators and additives play in the production of mouldings
11. the function fibre materials, fabrics, orientations and their combinations play in the production of mouldings
12. how to build up laminates (including orientation and balance of plies) to minimise spring and distortion in composite mouldings
13. the function core, insert and filler materials play in the production of mouldings
14. how to visually identify raw and finished composite materials
15. how to identify materials by product codes
16. the type of production tooling used for producing composite mouldings
17. the identification of common defects in production tooling
18. how to prepare patterns, moulds and tooling, including the correct selection and use of surface sealers and release agents
19. the correct methods of storage, thawing and handling of pre-preg materials (including monitoring temperature, storage life and out-life)
20. the method used in the application of pre-preg materials to tooling surfaces (including methods of tailoring and cutting)
21. the correct method of storing and handling ancillary and consumable materials
22. how to use ancillary and consumable materials (such as release films, breather fabrics, bagging films, tapes) to meet performance requirements (such as temperature and compatibility)
23. the tools and equipment used in the pre-preg laminating activities, and their care, preparation and control procedures
24. the common problems that can occur during the lay-up process (including modifications to the ply lay-up, and defects such as contamination and distortion)
25. how defects can be prevented during the pre-preg laminating activity
26. the cure cycles (including temperature and pressure ramps, dwell times, post curing)
27. the importance of monitoring the cure cycle (using thermocouples, probes, chart recorders and data logs)
28. the procedures and methods used for removing mouldings from production tooling
29. the identification of common defects in the composite moulding (such as de-lamination, voids, contaminants)
30. the care and safe handling of production tooling and composite mouldings throughout the production cycle
31. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following during the moulding activities:

   1. use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, planning and quality control documentation)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. maintain a safe working environment for the moulding activities
   4. check that all tools and equipment to be used are correct for the operation to be carried out and are in a safe and usable condition
   5. follow safe practice/approved moulding techniques at all times
   6. return all tools and equipment to the correct location on completion of the moulding activities
   7. segregate and dispose of waste materials using the correct procedure
   8. leave the work area in a safe and appropriate condition on completion of the activities

2. Carry out three of the following activities when preparing production tooling:

   1. check that tooling is correct and complete
   2. clean tooling and remove resin build-ups
   3. check for surface defects
   4. correctly apply sealers/release agents
   5. clean and store tooling suitably after use

3. Carry out all of the following activities to prepare materials for production:

   1. obtain correct materials for the activity
   2. thaw material removed from freezer storage
   3. identifying defects in pre-preg materials
   4. confirm that materials are fit for purpose and in life
   5. check availability of ancillary materials required
   6. cut materials to correct shape and orientation
   7. check materials when provided in kit form
   8. identify and protect materials in the work area

4. Produce a range of mouldings, using two of the following types of production tool:

   1. pattern
   2. mandrels
   3. metal
   4. tooling block
   5. glass pre-preg
   6. carbon pre-preg
   7. female tooling
   8. male tooling
   9. multi-part tools
   10. matched tooling
   11. closed tooling

5. Produce a range of mouldings incorporating two of the following in the lay-up:

   1. butt joins
   2. overlap joins
   3. staggered joins
   4. orientated plies
   5. inverted plies
   6. balancing plies
   7. inserts
   8. fixtures

6. Produce a range of mouldings incorporating four of the following shape features:

   1. internal corners
   2. external corners
   3. horizontal surface
   4. vertical surface
   5. double curvature
   6. concave surface
   7. convex surfaces
   8. return surfaces
   9. joggle details
   10. nett edges

7. Produce a range of mouldings using three of the following methods:

   1. production of ply templates
   2. nesting of ply templates
   3. material cutting & kitting
   4. shaped locators
   5. joining boards
   6. loose tooling
   7. intensifiers
   8. vacuum de-bulk
   9. hot de-bulk
   10. pressure de-bulk
   11. moulded datum features
   12. placement jigs
   13. laser projection placement
   14. video feedback placement

8. Produce a range of mouldings using one type of resin from:

   1. bio resin
   2. thermoplastic
   3. epoxy
   4. phenolic
   5. bismaleimide
   6. cyanate ester
   7. other specific resin

9. Produce a range of mouldings using techniques for one type of fibre from:

   1. natural fibre
   2. thermoplastic
   3. glass
   4. aramid
   5. carbon
   6. hybrid
   7. other specific fibre

10. Produce a range of mouldings using one types of reinforcement from:

    1. continuous
    2. uni-directional
    3. tapes
    4. tissues/veils
    5. woven
    6. braids
    7. multi-axis

11. Produce a range of mouldings using one types of core material (where applicable to the Sector or process):

    1. solid timber
    2. end grain balsa
    3. thermoplastic core
    4. rigid foam
    5. syntactic core
    6. expanding core
    7. fibrous honeycomb
    8. aluminium honeycomb
    9. other specific core material

12. Use one of the following methods when using core materials (where applicable to the Sector or process):

    1. core templates
    2. pre-shaping core
    3. core chamfers
    4. core splicing
    5. peel plies
    6. bonding paste
    7. edge filling
    8. adhesive/resin films
    9. potting/filler compound
    10. single stage curing
    11. multi-stage curing

13. Prepare the moulding for temperature curing using one of the following methods:

    1. oven
    2. autoclave
    3. heated tools/moulds
    4. heat mats
    5. heated press
    6. curing lamps
    7. infrared heating
    8. UV curing
    9. electro-magnetic inductance
    10. micro-wave
    11. other specific method

14. Preparing the moulding for pressure consolidation using one of the following methods:

    1. vacuum bags
    2. hot de-bulk
    3. pressure de-bulk
    4. pressure bags
    5. thermal mould expansion
    6. fibre tensioning
    7. press
    8. autoclave

15. Where vacuum bags are used, use two of the following processes/methods:

    1. check vacuum integrity
    2. surface bagging
    3. envelope bagging
    4. multi-part envelope bags
    5. internal bagging
    6. through-tube bagging
    7. pleats and tucks
    8. reusable bagging
    9. use of reusable vacuum fittings

16. Produce a range of mouldings which comply with one of the following standards:

    1. BS, ISO or BSEN standards and procedures
    2. customer standards and requirements
    3. company standards and procedures
    4. recognised compliance agency/body standards

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31 Mar 2019

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Current

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Original

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Semta

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SEMMME2-32

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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5221

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engineering; manufacturing; mechanical; producing; pre-preg; lamination; composite moulds; carbon pre-preg; techniques; methods; equipment

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